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Home › Lincoln › 2002 › Navigator RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 5 (Transfer Case - Automatic Shift) › Disassembly And Assembly › Transfer Case › Disassembly

Transfer Case: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove the transfer case (7A195). For additional information, refer to TRANSFER CASE -4R70W TRANSMISSION  or TRANSFER CASE -4R100 TRANSMISSION  .
  2. Using the special tool, secure the transfer case to a work bench.
    Fig 1: Securing Transfer Case To Work Bench
    G03444732Courtesy of FORD MOTOR CO.
  3. Using a suitable tool, remove the oil seal, if necessary.
    Fig 2: Removing Oil Seal
    G03444733Courtesy of FORD MOTOR CO.
  4. Remove the coil wire pin from the electrical connector.
    1. Remove the wire connector spacer.
    2. Remove the coil wire pin.
      • Use an electrical connector pin extractor tool.
    Fig 3: Removing Coil Wire Pin From Electrical Connector
    G03444734Courtesy of FORD MOTOR CO.
    5. CAUTION: Note each sensor wire pin location for correct installation.
    Fig 4: Removing Front And Rear Output Shaft Speed Sensor Wire Pins
    G03444735Courtesy of FORD MOTOR CO.
  5. Remove the front and rear output shaft speed sensor wire pins from the electrical connector.
    • Use an electrical connector pin extractor tool.
  6. Remove the transfer case shift motor (7G360).
    1. Remove the bolts.
    2. Remove the transfer case shift motor.
    Fig 5: Removing Transfer Case Shift Motor
    G03444736Courtesy of FORD MOTOR CO.
  7. Remove the rear output shaft speed sensor (7F293).
    1. Remove the bolt (7A443).
    2. Remove the rear output shaft speed sensor.
    Fig 6: Removing Rear Output Shaft Speed Sensor
    G03444737Courtesy of FORD MOTOR CO.
  8. Remove the front output shaft speed sensor (7F293).
    1. Remove the bolt (7A443).
    2. Remove the front output shaft speed sensor.
    Fig 7: Removing Front Output Shaft Speed Sensor
    G03444738Courtesy of FORD MOTOR CO.
  9. Remove the extension housing (7085).
    1. Remove the bolts.
    2. Remove the extension housing.
    Fig 8: Removing Extension Housing
    G03444739Courtesy of FORD MOTOR CO.
  10. Remove and discard the sealing ring.
    Fig 9: Removing And Discard Sealing Ring
    G03444740Courtesy of FORD MOTOR CO.
  11. Remove the tone wheel spacer (17291) and the tone wheel (7G450).
    Fig 10: Removing Tone Wheel Spacer And Tone Wheel
    G03444741Courtesy of FORD MOTOR CO.
    12. NOTE: Lift up on the output shaft (7061) while removing the snap ring (7917).
    Fig 11: Removing Snap Ring
    G03444742Courtesy of FORD MOTOR CO.
  12. Remove the snap ring.
    13. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts (7A443).
    Fig 12: Removing Bolts
    G03444743Courtesy of FORD MOTOR CO.
  13. Remove the 20 bolts.
  14. Separate the transfer case (7005) halves.
    • Use the pry bosses to separate the case halves.
    Fig 13: Separating Transfer Case Halves
    G03444744Courtesy of FORD MOTOR CO.
  15. Remove the coil (7G361), if necessary.
    1. Remove the nuts.
    2. Remove the coil.
    Fig 14: Removing Coil
    G03444745Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the rear output shaft support bearing (7025), if necessary.
    Fig 15: Removing Rear Output Shaft Support Bearing
    G03444746Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the front output shaft rear bearing (7025), if necessary.
    Fig 16: Removing Front Output Shaft Rear Bearing
    G03444747Courtesy of FORD MOTOR CO.
  18. Remove the snap ring (7917).
    Fig 17: Removing Snap Ring
    G03444748Courtesy of FORD MOTOR CO.
  19. Remove the thrust bearing assembly.
    1. Remove the thick thrust bearing race (7A387).
    2. Remove the thrust bearing (7D221).
    3. Remove the thin thrust bearing race (7Z111).
    Fig 18: Removing Thrust Bearing Assembly
    G03444749Courtesy of FORD MOTOR CO.
  20. Remove the lockup shift fork spring (7219).
    Fig 19: Removing Lockup Shift Fork Spring
    G03444750Courtesy of FORD MOTOR CO.
  21. Remove the cam/coil housing (7G362).
    Fig 20: Removing Cam/Coil Housing
    G03444751Courtesy of FORD MOTOR CO.
  22. Remove the steel balls (7A534) and the cam (7R428).
    1. Remove the steel balls.
    2. Remove the cam.
    Fig 21: Removing Steel Balls And Cam
    G03444752Courtesy of FORD MOTOR CO.
  23. Remove the wave spring (7E085).
    Fig 22: Removing Wave Spring
    G03444753Courtesy of FORD MOTOR CO.
  24. Remove and discard the snap ring (7917).
    Fig 23: Removing And Discard Snap Ring
    G03444754Courtesy of FORD MOTOR CO.
    25. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
    Fig 24: Removing Clutch Pack Assembly
    G03444755Courtesy of FORD MOTOR CO.
  25. Remove the clutch pack assembly (7C108).
  26. Remove the front output shaft tone wheel (7G450).
    Fig 25: Removing Front Output Shaft Tone Wheel
    G03444756Courtesy of FORD MOTOR CO.
  27. Remove the drive chain assembly (7A029) and the sprockets as an assembly.
    Fig 26: Removing Drive Chain Assembly And Sprockets
    G03444757Courtesy of FORD MOTOR CO.
  28. Remove the thrust bearing assembly.
    1. Remove the thrust washer (7C341).
    2. Remove the thrust bearing (7D221).
    3. Remove the thrust washer (7C341).
    Fig 27: Removing Thrust Bearing Assembly
    G03444758Courtesy of FORD MOTOR CO.
  29. Remove the lockup collar and assembly (7106) and the lockup fork (7289) as an assembly.
    Fig 28: Removing Lockup Collar And Assembly
    G03444759Courtesy of FORD MOTOR CO.
  30. Remove and clean the oil pan magnet (7L027).
    Fig 29: Removing And Clean Oil Pan Magnet
    G03444760Courtesy of FORD MOTOR CO.
  31. Remove the oil pump assembly (7A149) and the output shaft (7061) as an assembly.
    Fig 30: Removing Oil Pump Assembly
    G03444761Courtesy of FORD MOTOR CO.
  32. Remove the reduction shift fork assembly (7289) and the reduction hub (7100) as an assembly.
    Fig 31: Removing Reduction Shift Fork Assembly
    G03444762Courtesy of FORD MOTOR CO.
  33. Remove the shift fork shaft (7240).
    Fig 32: Removing Shift Fork Shaft
    G03444763Courtesy of FORD MOTOR CO.
    34. WARNING: Do not disassemble the shift cam assembly (7F063).
    Fig 33: Removing Shift Cam Assembly
    G03444764Courtesy of FORD MOTOR CO.
  34. Remove the shift cam assembly.
  35. Using the special tool, remove the oil seal.
    Fig 34: Removing Oil Seal
    G03444765Courtesy of FORD MOTOR CO.
  36. Remove the front planet (7A398).
    1. Depress the snap ring (7917).
    2. Remove the front planet.
    Fig 35: Removing Front Planet
    G03444766Courtesy of FORD MOTOR CO.
  37. Using a drift and a hammer, remove the needle bearing, if necessary.
    Fig 36: Removing Needle Bearing
    G03444767Courtesy of FORD MOTOR CO.
  38. If front planet support bearing removal is necessary, remove the snap ring.
    Fig 37: Removing Snap Ring
    G03444768Courtesy of FORD MOTOR CO.
  39. Using a suitable press and the special tool, remove the front planet support bearing.
    Fig 38: Removing Front Planet Support Bearing
    G03444769Courtesy of FORD MOTOR CO.
  40. Remove the ring gear (7A153), if necessary.
    1. Remove the snap ring (7064).
    2. Remove the ring gear.
    Fig 39: Removing Ring Gear
    G03444770Courtesy of FORD MOTOR CO.
  41. Remove the snap ring.
    Fig 40: Removing Snap Ring
    G03444771Courtesy of FORD MOTOR CO.
    42. CAUTION: Do not let the front output shaft fall when removing the snap ring (7917).
    Fig 41: Removing Front Output Shaft
    G03444772Courtesy of FORD MOTOR CO.
  42. Remove the front output shaft.
    1. Remove the snap ring.
    2. Remove the front output shaft.
  43. Using the special tools, remove the front output shaft support bearing (7025), if necessary.
    Fig 42: Removing Front Output Shaft Support Bearing
    G03444773Courtesy of FORD MOTOR CO.
  44. Using the special tools, remove the oil seal (7B215).
    Fig 43: Removing Oil Seal
    G03444774Courtesy of FORD MOTOR CO.
  45. Using a suitable tool, remove the shifter shaft seal (7288), if necessary.
    Fig 44: Removing Shifter Shaft Seal
    G03444775Courtesy of FORD MOTOR CO.
  46. Remove the dust shield (7C016), if necessary.
    Fig 45: Removing Dust Shield
    G03444776Courtesy of FORD MOTOR CO.
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